平纹编织CFRP/Al胶接结构断裂行为与安全性评估

Fracture Behavior and Safety Assessment of Plain Woven CFRP/Al Bonded Joints

  • 摘要: 胶接结构因优于传统连接而在航空复合材料-金属混合连接中广泛应用,然而异质界面刚度差异易导致脱粘与分层等竞争性失效。针对复合材料-金属异种材料胶接结构界面失效问题,开展了I型双悬臂梁和II型端部缺口弯曲断裂韧性试验与数值模拟研究。通过试验测定了铝合金/碳纤维增强复合材料(Al/CFRP)胶接接头的I型和II型断裂韧性参数,随后建立双线性内聚力模型,将试验获取的断裂韧性参数代入计算,有效验证了模型的准确性。结果表明:在I型载荷下,异种材料界面的性能差异诱发了竞争失效机制,导致失效模式从胶层内聚失效迁移为复合材料内部的层间失效;在Ⅱ型载荷下,失效模式表现出伴随CFRP表层树脂剪切破坏的界面失效特征。最后揭示了非预制裂纹(NPC)结构因缺乏尖锐初始裂纹而表现出的宏观钝化增韧与高起裂阻力特征,并验证了利用预制裂纹(PC)参数预测NPC承载力下限的可行性,预测值较试验最不利情况仍保守约4%,为异质胶接结构的损伤容限设计提供一种偏于安全的保守评估策略与工程参考。

     

    Abstract: Adhesively bonded structures offer significant advantages over traditional joining methods and are widely used in aerospace composite-metal hybrid joints. However, stiffness discrepancies at the heterogeneous interface often lead to competitive failures such as debonding and delamination. To address interfacial failure in these structures, Mode I Double Cantilever Beam and Mode II End Notched Flexure fracture toughness tests and numerical simulations were conducted. The Mode I and Mode II fracture energy parameters of Al/CFRP bonded joints were experimentally determined. Subsequently, a finite element model incorporating a bilinear Cohesive Zone Model was established and effectively validated using experimentally derived parameters. The results indicated that under Mode I loading, the property mismatch at the dissimilar interface induces a competitive failure mechanism, causing a failure mode transition from initial cohesive failure within the adhesive layer to interlaminar delamination within the composite. Under Mode II loading, the failure mode exhibits interfacial failure characteristics accompanied by shear failure of the CFRP surface resin. Finally, the study revealed that Non-Pre-Cracked (NPC) structures exhibit macroscopic blunting toughening and high crack initiation resistance due to the absence of sharp initial cracks. Furthermore, the feasibility of predicting the lower bound of the load-carrying capacity of NPC structures using Pre-Cracked (PC) parameters was verified. The predicted limit load remains conservatively about 4% lower than the most unfavorable experimental case, thereby providing a safe and conservative assessment strategy and engineering reference for the damage tolerance design of heterogeneous bonded structures.

     

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